Contact line having insulating spacer therein and method of forming same

ABSTRACT

One aspect of the disclosure relates to an integrated circuit structure. The integrated circuit structure may include: a contact line being disposed within a dielectric layer and providing electrical connection to source/drain epitaxial regions surrounding a set of fins, the contact line including: a first portion of the contact line electrically isolated from a second portion of the contact line by a contact line spacer, wherein the first portion and the second portion each include a liner layer and a metal, the liner layer separating the metal from the dielectric layer and the source/drain epitaxial regions, and wherein the metal is directly in contact with the contact line spacer.

BACKGROUND Technical Field

The present disclosure relates to integrated circuits, and more particularly, to contact lines having insulating spacers therein, and a method of forming the same.

Related Art

Transistors, e.g., field-effect-transistors (FETs), generally include source, drain, and gate terminals. The gate terminal controls current between the source and drain terminals. Transistors may be formed over a substrate and may be disposed within a dielectric layer, e.g., inter-level dielectric layer. Contacts may be formed to each of the source, drain, and gate terminals through the dielectric layer in order to provide electrical connection between the transistor and other semiconductor devices that may be formed subsequent to the transistor in other metal levels. The contacts to the source and drain terminals of the FET are typically formed in an opening that extends through a dielectric layer.

Contacts may be formed to include a liner layer, such as a refractory metal layer, barrier layer, or nucleation layer, which substantially lines or coats the opening. Additionally, a conductive metal may be formed over the liner layer to substantially fill the opening. Further, a planarization technique may be employed to remove any material outside of the opening to form contact lines.

Depending on the application for the integrated circuit, it may be desirable to provide an insulating spacer within contact lines to electrically isolate one portion of a contact line from another. However, as integrated circuits continue to be scaled down, the real estate on the integrated circuit becomes more valuable in order to maintain the performance characteristics comparable to that of larger integrated circuits.

SUMMARY

A first aspect of the disclosure relates to a method of forming contact line spacers. The method may include: forming a liner layer within a first trench over an exposed first source/drain epitaxial region of a fin-shaped field-effect-transistor (FINFET) to substantially line the first trench, and forming the liner layer within a second trench over an exposed second source/drain epitaxial region of the FINFET to substantially line the second trench; forming a sacrificial material over the liner layer within the first trench and the second trench to substantially fill the first trench and the second trench; removing a portion of the sacrificial material and a portion of the liner layer from the first trench to expose a first portion of the first source/drain epitaxial region thereunder and from the second trench to expose a second portion of the second source/drain epitaxial region thereunder; forming a dielectric film over the exposed first portion of the first source/drain epitaxial region within the first trench to form a first contact line spacer, and forming the dielectric film over the exposed second portion of the second source/drain epitaxial region within the second trench to form a second contact line spacer; and planarizing to a top surface of the dielectric layer.

A second aspect of the disclosure relates to a method of forming contact line spacers. The method may include: forming a liner layer within a first trench over an exposed first source/drain region of a fin-shaped field-effect-transistor (FINFET) to substantially line the first trench, and forming the liner layer within a second trench over an exposed second source/drain region of the FINFET to substantially line the second trench; forming a sacrificial material over the liner layer within the first trench and the second trench to substantially fill the first trench and the second trench; removing a portion of the sacrificial material and a portion of the liner layer from the first trench to expose a first portion of the first source/drain region thereunder and from the second trench to expose a second portion of the second source/drain region thereunder; forming a dielectric film over the exposed first portion of the first source/drain region within the first trench to form a first contact line spacer, and forming the dielectric film over the exposed second portion of the second source/drain region within the second trench to form a second contact line spacer; and planarizing to a top surface of the dielectric layer.

A third aspect of the disclosure relates to an integrated circuit structure. The integrated circuit structure may include: a contact line being disposed within a dielectric layer and providing electrical connection to source/drain epitaxial regions surrounding a set of fins, the contact line including: a first portion of the contact line electrically isolated from a second portion of the contact line by a contact line spacer, wherein the first portion and the second portion each include a liner layer and a metal, the liner layer separating the metal from the dielectric layer and the source/drain epitaxial regions, and wherein the metal is directly in contact with the contact line spacer.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of this disclosure will be more readily understood from the following detailed description of the various aspects of the invention taken in conjunction with the accompanying drawings that depict various embodiments of the disclosure, in which:

FIGS. 1A-1B show a preliminary integrated circuit structure with FIG. 1A showing a top-down view of the preliminary integrated circuit structure and FIG. 1B showing a cross-sectional view of the preliminary integrated circuit structure taken along line A-A of FIG. 1A.

FIGS. 2A-2B show the integrated circuit structure undergoing aspects of a method according to embodiments of the disclosure with FIG. 2A showing a top-down view of the integrated circuit structure and FIG. 2B showing a cross-sectional view of the integrated circuit structure taken along line A-A of FIG. 2A.

FIGS. 3A-3B show the integrated circuit structure undergoing aspects of a method according to embodiments of the disclosure with FIG. 3A showing a top-down view of the integrated circuit structure and FIG. 3B showing a cross-sectional view of the integrated circuit structure taken along line A-A of FIG. 3A.

FIGS. 4A-4B show the integrated circuit structure undergoing aspects of a method according to embodiments of the disclosure with FIG. 4A showing a top-down view of the integrated circuit structure and FIG. 4B showing a cross-sectional view of the integrated circuit structure taken along line A-A of FIG. 4A.

FIGS. 5A-5B show the integrated circuit structure undergoing aspects of a method according to embodiments of the disclosure with FIG. 5A showing a top-down view of the integrated circuit structure and FIG. 5B showing a cross-sectional view of the integrated circuit structure taken along line A-A of FIG. 5A.

FIGS. 6A-6B show the integrated circuit structure undergoing aspects of a method according to embodiments of the disclosure with FIG. 6A showing a top-down view of the integrated circuit structure and FIG. 6B showing a cross-sectional view of the integrated circuit structure taken along line A-A of FIG. 6A.

FIGS. 7A-7B show the integrated circuit structure undergoing aspects of a method according to embodiments of the disclosure with FIG. 7A showing a top-down view of the integrated circuit structure and FIG. 7B showing a cross-sectional view of the integrated circuit structure taken along line A-A of FIG. 7A.

FIGS. 8A-8B show the integrated circuit structure undergoing aspects of a method according to embodiments of the disclosure with FIG. 8A showing a top-down view of the integrated circuit structure and FIG. 8B showing a cross-sectional view of the integrated circuit structure taken along line A-A of FIG. 8A.

FIGS. 9A-9B show the integrated circuit structure undergoing aspects of a method according to embodiments of the disclosure with FIG. 9A showing a top-down view of the integrated circuit structure and FIG. 9B showing a cross-sectional view of the integrated circuit structure taken along line A-A of FIG. 9A.

FIGS. 10A-10B show the integrated circuit structure undergoing aspects of a method according to embodiments of the disclosure with FIG. 10A showing a top-down view of the integrated circuit structure and FIG. 10B showing a cross-sectional view of the integrated circuit structure taken along line A-A of FIG. 10A.

FIGS. 11A-11B show the integrated circuit structure undergoing aspects of a method according to embodiments of the disclosure with FIG. 11A showing a top-down view of the integrated circuit structure and FIG. 11B showing a cross-sectional view of the integrated circuit structure taken along line A-A of FIG. 11A.

FIGS. 12A-12B show the integrated circuit structure undergoing aspects of a method according to embodiments of the disclosure with FIG. 12A showing a top-down view of the integrated circuit structure and FIG. 12B showing a cross-sectional view of the integrated circuit structure taken along line A-A of FIG. 12A.

FIGS. 13A-13B show the integrated circuit structure undergoing aspects of a method according to embodiments of the disclosure with FIG. 13A showing a top-down view of the integrated circuit structure and FIG. 13B showing a cross-sectional view of the integrated circuit structure taken along line A-A of FIG. 13A.

FIGS. 14A-14B show the integrated circuit structure undergoing aspects of a method according to embodiments of the disclosure with FIG. 14A showing a top-down view of the integrated circuit structure and FIG. 14B showing a cross-sectional view of the integrated circuit structure taken along line A-A of FIG. 14A.

FIGS. 15A-15B show the integrated circuit structure undergoing aspects of a method according to embodiments of the disclosure with FIG. 15A showing a top-down view of the integrated circuit structure and FIG. 15B showing a cross-sectional view of the integrated circuit structure taken along line A-A of FIG. 15A.

FIGS. 16A-16B show a resulting integrated circuit structure having undergone aspects of a method according to embodiments of the disclosure with FIG. 16A showing a top-down view of the integrated circuit structure and FIG. 16B showing a cross-sectional view of the integrated circuit structure taken along line A-A of FIG. 16A.

FIG. 17 shows a cross-sectional view of the integrated circuit structure of FIG. 16A taken along line B-B.

FIG. 18 shows a cross-sectional view of the integrated circuit structure of FIG. 16A taken along line C-C.

FIGS. 19A-19B show the integrated circuit structure undergoing aspects of a method according to embodiments of the disclosure with FIG. 19A showing a top-down view of the integrated circuit structure and FIG. 19B showing a cross-sectional view of the integrated circuit structure taken along line A-A of FIG. 19A.

FIGS. 20A-20B show the integrated circuit structure undergoing aspects of a method according to embodiments of the disclosure with FIG. 20A showing a top-down view of the integrated circuit structure and FIG. 20B showing a cross-sectional view of the integrated circuit structure taken along line A-A of FIG. 20A.

FIGS. 21A-21B show the integrated circuit structure undergoing aspects of a method according to embodiments of the disclosure with FIG. 21A showing a top-down view of the integrated circuit structure and FIG. 21B showing a cross-sectional view of the integrated circuit structure taken along line A-A of FIG. 21A.

FIG. 22 shows a cross-sectional view of the integrated circuit structure of FIG. 21A taken along line B-B.

FIG. 23 shows a cross-sectional view of the integrated circuit structure of FIG. 21A taken along line C-C.

It is noted that the drawings of the disclosure are not to scale. The drawings are intended to depict only typical aspects of the disclosure, and therefore should not be considered as limiting the scope of the invention. In the drawings, like numbering represents like elements between the drawings.

DETAILED DESCRIPTION

The present disclosure relates to integrated circuits, and more particularly, to spacers between source/drain terminal contact lines, and a method of forming the same.

FIG. 1A shows a top-down view of a preliminary integrated circuit (IC) structure 100. FIG. 1B shows a cross-sectional view of preliminary IC structure 100 taken along line A-A of FIG. 1A. Referring to FIGS. 1A-1B together, IC structure 100 may include a substrate 102 (FIG. 1B) from which a set of fins, e.g., fin 104 (FIG. 1B), were patterned. In one embodiment, substrate 102 may include a bulk substrate. Bulk substrates generally include a layer or wafer of semiconducting material without buried insulator layers contained therein, in contrast to semiconductor-on-insulator (SOI) substrates which include both semiconducting and insulating materials. Conventional fin-shaped field-effect-transistors (FINFETs) are formed within SOI substrate materials, but can be adapted for use within a bulk substrate despite the absence of buried insulator materials. Substrate 102 can be composed of any currently known or later developed semiconductor material, which may include without limitation, silicon, germanium, silicon carbide, and those consisting essentially of one or more III-V compound semiconductors having a composition defined by the formula Al_(X1)Ga_(X2)In_(X3)As_(Y1)P_(Y2)N_(Y3)Sb_(Y4), where X1, X2, X3, Y1, Y2, Y3, and Y4 represent relative proportions, each greater than or equal to zero and X1+X2+X3+Y1+Y2+Y3+Y4=1 (1 being the total relative mole quantity). Other suitable substrates include II-VI compound semiconductors having a composition Zn_(A1)Cd_(A2)Se_(B1)Te_(B2), where A1, A2, B1, and B2 are relative proportions each greater than or equal to zero and A1+A2+B1+B2=1 (1 being a total mole quantity). Furthermore, the entirety of bulk substrate 102 or a portion thereof may be strained. In other embodiments, substrate 102 may include an SOI substrate (not shown). In such an embodiment, set of fins, e.g., fin 104, may be patterned from a semiconducting layer overlying an insulating layer overlying another semiconducting layer as is known in the art.

Fins, e.g., fin 104, may be patterned and etched from substrate 102 as known in the art. While embodiments of the disclosure are described relative to fin-shaped field-effect-transistors (FINFETS), it is to be understood that embodiments of the disclosure are equally applicable to other types of FETs. While only one fin has been shown in FIGS. 1A-1B, additional fins will be described elsewhere herein, and it is to be understood that there may be any number of fins adjacent to fin 104 on substrate 102. Further, there may be shallow trench isolation (STI) regions (not shown in FIGS. 1A-1B but described elsewhere herein) between adjacent fins.

Gate structures 110 a, 110 b may overly the set of fins, e.g., 104. Gate structures 110 a, 110 b may be formed such that gate structures 110 a, 110 b are perpendicular to fin 104 and substantially surround fin 104. Gate structures 110 a, 110 b may also be formed such that gate structures 110 a, 110 b are over at least a portion of substrate 102. Gate structures 110 a, 110 b may each include a layer having a high dielectric constant (high-k layer) 112 a, 112 b (FIG. 1B). Overlying high-k layers 112 a, 112 b may be work function metal layers 114 a, 114 b (FIG. 1B), respectively, and overlying work function metal layers 114 a, 114 b may be gate conductors 116 a, 116 b (FIG. 1B), respectively. Further, gate structures 110 a, 110 b may each include a gate cap layer 118 a, 118 b overlying gate conductor 116 a, 116 b. While two adjacent gate structures are shown and described herein, the disclosure is equally applicable to other types of FETs having more or less gate structures. Additionally, it is to be understood that gate structures 110 a, 110 b may include additional materials and/or layer known in gate structure construction without departing from aspects of the disclosure.

High-k layers 112 a, 112 b may each include an insulating material whose dielectric constant (k), is greater than that of silicon dioxide, e.g., greater than 4.0. High-k layers 112 a, 112 b may include, for example, at least one of: hafnium oxide, hafnium silicate, nitride hafnium silicate, zirconium oxide, zirconium silicate, titanium oxide, lanthanum oxide, yttrium oxide, aluminum oxide, or combinations thereof. Work function metal layers 114 a, 114 b may each act as a doping source, and a different work function setting metal can then be employed depending on whether a n-type field-effect-transistor (NFET) or a p-type field-effect-transistor (PFET) device is desired. Thus, the same gate conductor 116 a, 116 b can be used in each of the devices, yet a different (if so desired) work function setting metal can be used in one or more devices to obtain a different doping polarity. By way of example only, suitable work function setting metals for use in PFET devices include, but are not limited to aluminum, dysprosium, gadolinium, and ytterbium. Suitable work function setting metals for use in NFET devices include, but are not limited to lanthanum, titanium, and tantalum. Gate conductors 116 a, 116 b may each include, for example, at least one of: titanium, titanium nitride, tungsten, tungsten nitride, copper, copper nitride, tantalum, or tantalum nitride. Gate cap layers 118 a, 118 b may each include, for example, at least one of: an oxide, e.g., silicon dioxide, or a nitride, e.g., silicon nitride.

Gate structures 110 a, 110 b may be formed as known in the art. For example, gate structures 110 a, 110 b may be formed by a gate-last process. In a gate-last process, a sacrificial or dummy gate structure (not shown) is first formed by depositing, patterning, and etching a sacrificial material, e.g., polysilicon, over and around fin 104 and over at least a portion of substrate 102, or by other conventional lithographic techniques. Subsequently, gate spacers 120 a, 120 b may be formed immediately adjacent to the dummy gate structure such that gate spacers 120 a, 120 b are also formed over and around fin 104 and over at least a portion of substrate 102. Gate spacers 120 a, 120 b may be formed by depositing, patterning, and etching gate spacer materials discussed herein, or by other lithographic techniques. Gate spacers 120 a, 120 b may each be formed on opposing sides of gate structures 110 a, 110 b such that gate spacers 120 a, 120 b are substantially perpendicular to fin 104 (into and out of the page). Gate spacers 120 a, 120 b may include, for example, at least one of: an oxide, e.g., silicon dioxide, or a nitride, e.g., silicon nitride.

As used herein, the term “depositing” may include any now known or later developed technique appropriate for the material being deposited, including but not limited to, for example: chemical vapor deposition (CVD), low-pressure CVD (LPCVD), plasma-enhanced CVD (PECVD), semi-atmosphere CVD (SACVD) high density plasma CVD (HDPCVD), rapid thermal CVD (RTCVD), ultra-high vacuum CVD (UHVCVD), limited reaction processing CVD (LRPCVD), metalorganic CVD (MOCVD), sputtering deposition, ion beam deposition, electron beam deposition, laser assisted deposition, thermal oxidation, thermal nitridation, spin-on methods, physical vapor deposition (PVD), atomic layer deposition (ALD), chemical oxidation, molecular beam epitaxy (MBE), plating, and evaporation.

“Etching” generally refers to the removal of material from a substrate or structures formed on the substrate. In some instances, it may be desirable to selectively remove material from certain areas of the substrate. In such an instance, a mask may be used to prevent the removal of material from certain areas of the substrate. There are generally two categories of etching, (i) wet etch and (ii) dry etch. Wet etching may be used to selectively dissolve a given material and leave another material relatively intact. Wet etching is typically performed with a solvent, such as an acid. Dry etching may be performed using a plasma which may produce energetic free radicals, neutrally charged, that react at the surface of the wafer. Neutral particles may attack the wafer from all angles, and thus, this process is isotropic. Ion milling, or sputter etching, bombards the wafer with energetic ions of noble gases from a single direction, and thus, this process is highly anisotropic. A reactive-ion etch (RIE) operates under conditions intermediate between sputter etching and plasma etching and may be used to produce deep, narrow features, such as STI trenches.

After gate spacers 120 a, 120 b are formed, source/drain epitaxial regions 124 may be formed over fin 104. Source/drain epitaxial regions 124 may be formed by forming a mask (not shown) over fins, e.g., fin 104, and patterning the mask to expose portions of the fins where epitaxial source/drain regions 124 are desired to be formed, and epitaxially growing any of the source/drain epitaxial materials discussed herein over the exposed portions of the fins. Source/drain epitaxial regions 124 may include an epitaxial material, e.g., silicon, silicon germanium, or other semiconducting material, that is doped with one of p-type or n-type dopants. P-type dopants may include but are not limited to: boron, indium, and gallium. P-type is element introduced to semiconductor to generate free hole (by “accepting” electron from semiconductor atom and “releasing” hole at the same time); acceptor atom must have one valence electron less than host semiconductor; boron is the most common acceptor in silicon technology; alternatives include indium and gallium (gallium features high diffusivity in silicon dioxide, and hence, oxide cannot be used as mask during gallium diffusion). N-type dopants may include but are not limited to: phosphorous, arsenic, antimony. N-type is element introduced to semiconductor to generate free electron (by “donating” electron to semiconductor); must have one more valance electron than semiconductor; common donors in silicon: phosphorous, arsenic, antimony and in gallium arsenic: sulphur, selenium, tin, silicon, and carbon.

In other embodiments, portions of the fins, e.g., fin 104, that are exposed by the mask may be directly doped with p-type or n-type dopants without epitaxial regions thereover to create source/drain regions from the fins. While not shown herein for brevity, epitaxial source/drain regions 124 may have a substantially diamond-like cross-sectional shape as known in the art but not shown herein for brevity. Epitaxial source/drain regions 124 may substantially surround the fins, e.g. fin 104. Further, source/drain epitaxial regions 124 may be doped with a p-type or n-type dopant depending on whether a PFET of NFET device is desired. Together, gate structures 110 a, 110 b and fins 104 having source/drain epitaxial regions 124 may form adjacent field-effect-transistors (FETs), e.g., FINFETs.

A “mask” is a material or stack of materials which may be formed over an underlying material which is to be processed. The mask may be patterned to have openings such that the underlying material is exposed. Subsequently, the underlying material may be processed where the underlying material is exposed by the openings in the mask. Once the underlying material is processed, the mask may be removed. Conventional masking materials include photoresist and nitride.

The terms “epitaxial growth and/or deposition” and “epitaxially formed and/or grown” mean the growth of a semiconductor material on a deposition surface of a semiconductor material, in which the semiconductor material being grown may have the same crystalline characteristics as the semiconductor material of the deposition surface. In an epitaxial deposition process, the chemical reactants provided by the source gases are controlled and the system parameters are set so that the depositing atoms arrive at the deposition surface of the semiconductor substrate with sufficient energy to move around on the surface and orient themselves to the crystal arrangement of the atoms of the deposition surface. Therefore, an epitaxial semiconductor material may have the same crystalline characteristics as the deposition surface on which it may be formed. For example, an epitaxial semiconductor material deposited on a { 100} crystal surface may take on a {100} orientation. In some embodiments, epitaxial growth and/or deposition processes may be selective to forming on semiconductor surfaces, and may not deposit material on dielectric surfaces, such as silicon dioxide or silicon nitride surfaces.

After source/drain epitaxial regions 124 are formed, the mask may be removed and a dielectric cap layer 130 may be formed. Dielectric cap layer 130 may be formed over exposed portions of the set of fins, e.g., fin 104, source/drain epitaxial regions 124, and over the dummy gate structure. Dielectric cap layer 130 may include, for example, at least one of: an oxide, e.g., silicon dioxide, or a nitride, e.g., silicon nitride. Additionally, an inter-level dielectric layer 132 may be formed over dielectric cap layer 130. Inter-level dielectric (ILD) layer 132 may include, for example, at least one of: silicon nitride, silicon oxide, fluorinated SiO₂ (FSG), hydrogenated silicon oxycarbide (SiCOH), porous SiCOH, boro-phospho-silicate glass (BPSG), silsesquioxanes, carbon doped oxides (i.e., organosilicates) that include atoms of silicon, carbon, oxygen, and/or hydrogen, thermosetting polyarylene ethers, SiLK (a polyarylene ether available from Dow Chemical Corporation), a spin-on silicon-carbon containing polymer material available from JSR Corporation, other low dielectric constant (<3.9) material, or layers thereof.

Dielectric cap layer 130 and ILD layer 132 may be planarized to a top surface of the dummy gate structure such that the dummy gate structure and spacers 120 a, 120 b are exposed.

Subsequently, the dummy gate structures are removed leaving openings where the dummy gate structures once were to expose a top surface of fins, e.g., fin 104, thereunder. The openings are then filled with high-k dielectric layer 112 a, 112 b, work function metal layers 114 a, 114 b, gate conductors 116 a, 116 b, and gate cap layer 118 a, 118 b as is known in the art to create gate structures 110 a, 110 b. Gate structures 110 a, 110 b are active gate structures which control current between source/drain epitaxial regions 124. The resulting structure after gate structures 110 a, 110 b are shown in FIGS. 1A-1B.

In other embodiments, gate structures 110 a, 110 b may be formed via a gate first process. In a gate-first process, active gate structures, e.g., gate structures 110 a, 110 b are formed at the outset instead of forming dummy gate structures as was previously described.

Referring now to FIGS. 2A-2B, a mask 136 may be formed, e.g., deposited, over IC structure 100 and patterned and etched to expose locations where etching of the underlying material is desired. For example, as shown, mask 136 may be patterned and etched to expose gate structures 110 a, 110 b, i.e., gate cap 118 a, 118 b of gate structures 110 a, 110 b, spacers 120 a, 120 b, portions of dielectric cap layer 130 that are adjacent to spacers 120 a, 120 b, and portions of ILD layer 132 that are adjacent to gate structures 110 a, 110 b. That is, mask 136 may be etched to expose gate structures 110 a, 110 b and areas over where source/drain epitaxial regions 124 are located.

As shown in FIGS. 3A-3B, a RIE etch may be performed on IC structure 100 such that portions of ILD layer 132 and dielectric cap layer 130 exposed by openings in mask 136 are removed to form trenches 139 a, 139 b, 139 c over source/drain epitaxial regions 124. The RIE etch is performed such that only horizontal portions of insulating materials, i.e., ILD layer 132 and dielectric cap layer 130, are removed. Therefore, source/drain epitaxial regions 124 are exposed. Vertical portions of dielectric cap layer 130 may remain. That is, vertical portions of dielectric cap layer 130 adjacent to spacers 120 a, 120 b and source/drain epitaxial regions 124 may remain. However, in other embodiments (not shown), it may be desirable to remove the vertical potions of dielectric cap layer 130 from adjacent to spacers 120 a, 120 b. In such an embodiment, the removal of the vertical portions of the dielectric cap layer 130 adjacent to spacers 120 a, 120 b may be removed by reactive ion etch (RIE). Additionally, in some embodiments (shown), STI regions 138 (FIG. 3A) between adjacent fins may also be exposed. As known in the art, STI regions may isolate one region of a substrate from an adjacent region of the substrate. One or more transistors of a given polarity may be disposed within an area isolated by the STI region.

Trenches 139 a, 139 b, 139 c may extend along source/drain epitaxial regions 124 and STI regions 138 as shown in FIG. 3A. As used herein, trench 138 a may refer to the trench that is formed over source/drain epitaxial region 124 between gate structure 110 a and ILD layer 132, trench 139 b may refer to the trench that is formed over source/drain epitaxial region 124 between gate structure 110 b and ILD layer 132, and trench 139 c may refer to the trench over source/drain epitaxial region 124 between gate structure 110 a and 110 b. After etching, mask 136 (FIGS. 3A-3B) may be removed as shown in FIGS. 4A-4B, which can be completed by using any no known or later developed resist strip, in-situ or ex-situ. As will be described herein, trenches 139 a, 139 b, 139 c facilitate the formation of contact lines to source/drain epitaxial regions 124.

Referring now to FIGS. 5A-5B, another mask 140 may be formed, e.g., deposited, over IC structure 100. Mask 140 may include an amorphous carbon portion 142 which covers exposed source/drain epitaxial regions 124 within trenches 139 a, 139 b, 139 c. Mask 140 may be patterned and etched to expose portions of gate structures 110 a, 110 b at locations where electrical connections to gate structures 110 a, 110 b are desired to be made. That is, mask 140 may be patterned and etched such that at least a portion of gate cap layer 118 a, 118 b is exposed. In some embodiments (shown), mask 140 may be patterned and etched such that spacers 120 a, 120 b and dielectric cap layer 130 adjacent to spacers 120 a, 120 b are also exposed. FIG. 5B shows a cross-section of IC structure 100 taken along line A-A. Therefore, FIG. 5B, shows spacer 120 a as being exposed, but not spacer 120 b. As shown in FIG. 5A, spacers 120 b may be exposed elsewhere within IC structure 100.

Referring now to FIGS. 6A-6B, the exposed portions of gate cap layer 118 a, 118 b (and in some instances, spacers 120 a, 120 b and dielectric cap layer 130) may be removed. That is, a RIE may be performed on IC structure 100 such that portions of gate cap layer 118 a, 118 b, spacers 120 a, 120 b, and dielectric cap layer 130 are removed until portions of gate conductors 116 a, 116 b are exposed. In doing so, portions of work function metal layers 114 a, 114 b and high-k dielectric layer 112 a, 112 b may also be exposed. As shown in FIGS. 7A-7B, mask 140 (FIGS. 6A-6B), including amorphous carbon portion 142 (FIGS. 6A-6B), may be removed by any now know or later developed resist strip, in-situ or ex-situ. The removal of mask 140 exposes ILD layer 132, source/drain epitaxial regions 124 and STI regions 138 within trenches 139 a, 139 b, 139 c, gate structures 110 a, 110 b, and portions of dielectric cap layer 130 that were previously covered by mask 140 including amorphous carbon portion 142.

Referring now to FIGS. 8A-8B, a liner layer 148 may be formed, e.g., deposited, over IC structure 100 such that liner layer 148 substantially coats the entire IC structure 100. In the embodiment shown, liner layer 148 may be formed over exposed ILD layer 132, exposed source/drain epitaxial regions 124 and exposed STI regions 138 (FIGS. 7A-7B) within trenches 139 a, 139 b, 139 c, gate structures 110 a, 110 b, and spacers 120 a, 120 b. Additionally, any remaining portions of dielectric cap layer 130 adjacent to spacers 120 a, 120 b, and source/drain epitaxial regions 124 may also be covered by liner layer 148. Since gate structures 110 a, 110 b have been partially etched at some locations, liner layer 148 may be in direct contact with the exposed portions of gate conductors 116 a, 116 b, work function metal layers 114 a, 114 b, and high-k layers 112 a, 112 b of gate structures 110 a, 110 b. This can best be seen with respect to gate structure 110 a in FIG. 8B.

In some embodiments, the processes as described with respect to FIGS. 5A-7B may be optional and the process as described with respect to FIGS. 8A-8B may immediately follow the process as described with respect to FIGS. 4A-4B. In such an embodiment, liner layer 148 may be formed over exposed ILD layer 132, exposed source/drain epitaxial regions 124, exposed STI regions 138 (FIGS. 3A-3B), spacers 120 a, 120 b, and gate cap layer 118 a, 118 b of gate structures 110 a, 110 b. Additionally, liner layer 148 may be formed over any remaining portions of dielectric cap layer 130 adjacent to spacers 120 a, 120 b and adjacent to source/drain epitaxial regions 124 within trenches 139 a, 139 b, 139 c. In any embodiment, liner layer 148 may include, for example, at least one of: titanium, titanium nitride, tantalum, tantalum nitride, combinations thereof, or other refractory metal having similar properties. Liner layer 148 may be formed to have a thickness of approximately 1 nanometer (nm) to approximately 10 nm, or more particularly, about 4 nm.

As shown in FIGS. 9A-9B, after liner layer 148 is formed, a sacrificial material 152 may be formed over liner layer 148. Sacrificial material 152 may include, for example, at least one of: amorphous carbon or amorphous silicon. Within trenches 139 a, 139 b, 139 c, sacrificial material 152 may be formed from over liner layer 148 over source/drain epitaxial regions 124 and STI regions 138 (FIGS. 7A-7B) and extend past a top surface of ILD layer 132 such that sacrificial material 152 covers liner layer 148 over ILD layer 132. Subsequently, sacrificial material 152 may be etched back such that sacrificial material 152 within trenches 139 a, 139 b, 139 c is planar with liner layer 148 over ILD layer 132. Additionally, where portions of gate conductors 116 a, 116 b were exposed as described with respect to FIGS. 5A-7B, sacrificial material 152 over exposed gate conductors 116 a, 116 b may be etched back to a top surface of liner layer 148 over ILD layer 132. The etch back process creates sacrificial contact lines 156 a, 156 b, 156 c over source/drain epitaxial regions 124 and STI regions 138 (FIG. 7A) within trenches 139 a, 139 b, 139 c. Additionally, where portions of gate conductors 116 a, 116 b were exposed as described with respect to FIGS. 5A-7B, sacrificial contact lines 158 a, 158 b may be formed over portions of gate structures 110 a, 110 b. As shown, sacrificial contact lines 156 a and sacrificial contact lines 158 a may be continuous with one another, and sacrificial contact lines 156 b and sacrificial contact lines 158 b may be continuous with one another.

Referring now to FIGS. 10A-10B, where FIG. 10B shows a cross-section of IC structure 100 along line A-A of FIG. 10A, another mask 164 is formed over IC structure 100. That is, mask 164 is formed over exposed portions of liner layer 148 and sacrificial material 152. Mask 164 may be patterned and etched at locations where contact line spacers are desired to be formed as will be described herein. Therefore, it is to be understood that the patterning and etching of mask 164 is not limited to the locations shown in FIGS. 10A-10B. Rather, patterning and etching of mask 164 may be altered from that which is shown in FIGS. 10A-10B without departing from aspects of the disclosure as described herein. In such locations, mask 164 may be patterned and etched along sacrificial contact lines 156 a, 156 b, 156 c to expose portions of liner layer 148 and sacrificial material 152 which are to be removed.

As shown in FIGS. 11A-11B, the exposed portions of liner layer 148 and sacrificial material 152 may be removed to expose source/drain epitaxial regions 124 (including dielectric cap layer 130 adjacent thereto) and/or STI regions 138 at the desired locations where contact line spacers are to be formed. In such an embodiment, a first etch, e.g., RIE etch using HBr, may be performed to remove the exposed sacrificial material 152 to expose liner layer 148 thereunder. Then, a second etch, e.g., RIE etch using Cl⁻ or wet etch using HCl, may be performed to remove the exposed liner layer 148 to expose source/drain epitaxial region 124 and/or STI region 138 thereunder. Such etch processes create openings 168 a, 168 b, 168 c within sacrificial contact lines 156 a, 156 b, 156 c. It is to be understood that the position of openings 168 a, 168 b, 168 c may be altered from that which is shown in FIGS. 11A-11B without departing from aspects of the disclosure as described herein. Subsequently, mask 164 (FIGS. 11A-11B) may be removed as shown in FIGS. 12A-12B.

Referring now to FIGS. 13A-13B, a dielectric film 172 may be formed over IC structure 100 within openings 168 a, 168 b, 168 c (FIG. 12A-12B). Subsequently, dielectric film 172 may be etched back or planarized to a surface of liner layer 148 over ILD layer 132 such that dielectric film 172 remains within openings 168 a, 168 b, 168 c over the exposed source/drain epitaxial regions 124 (including dielectric cap layer 130 adjacent thereto) and/or STI regions 138 within trenches 139 a, 139 b, 139 c. The remaining portions of dielectric film 172 form contact line spacers 174 a, 174 b, 174 c. Dielectric film 172 may include, for example, a nitride, oxynitride, oxycarbide, oxycarbo nitride, oxyborocarbide, oxyboronitride or an oxide.

As shown in FIGS. 14A-14B, sacrificial material 152 may be removed from trenches 138 a, 138 b, 138 c (FIGS. 13A-13B) to expose liner layer 148 thereunder. Sacrificial material 152 may be removed by etching, e.g., a RIE etch. Referring now to FIGS. 15A-15B, a metal 178 may be formed over exposed liner layer 148 and contact line spacers 174 a, 174 b, 174 c to form contact lines 180 a, 180 b, 180 c. Metal 178 may include for example, at least one of: tungsten, cobalt, or copper. Subsequently, IC structure 100 (FIGS. 15A-15B) may be planarized to a top surface of ILD layer 132 to create a resulting IC structure 190 as shown in FIGS. 16A-16B.

IC structure 190 may include ILD layer 132 over a set of fins, e.g., including fin 104 (FIG. 16B). Within ILD layer 132, one or more gate structures 110 a, 110 b may be disposed perpendicular to fins, e.g., fin 104, such that gate structure 110 a, 110 b substantially surround fins, e.g., fin 104. Further, source/drain epitaxial regions 124 may be disposed such that source/drain epitaxial regions 124 (FIG. 16B) are over and substantially surround the fins, e.g., fin 104. Source/drain epitaxial regions 124 may be disposed on opposing sides of gate structures 110 a, 110 b. Source/drain contact lines 180 a, 180 b, 180 c may be disposed over source/drain epitaxial regions 124 (and/or in some cases, over STI region 138 (FIGS. 12A)) within ILD layer 132. Source/drain contact lines 180 a, 180 b, 180 c may include portions of liner layer 148 over source/drain epitaxial regions 124 (and/or in some cases, over STI region 138) within ILD layer 132. Source/drain contact lines 180 a, 180 b, 180 c may also include portions of metal 178 within liner layer 148. As known in the art, contact lines 180 a, 180 b, 180 c provide electrical connection between source/drain epitaxial regions 124 and structures which are to be fabricated in metal levels over ILD layer 132.

Source/drain contact lines 180 a, 180 b, 180 c may include contact line spacers 174 a, 174 b, 174 c therein. Contact line spacers 174 a, 174 b, 174 c may be composed of dielectric film 172 and provide electrical isolation between portions of source/drain contact lines 180 a, 180 b, 180 c such that the portions of source/drain contact lines 180 a, 180 b, 180 c separated by contact line spacers 174 a, 174 b, 174 c may be considered distinct source/drain contact lines.

In some embodiments, IC structure 190 may include gate contacts 182 a, 182 b which are in electrical connection with source/drain contact lines 180 a, 180 b, 180 c. In such an embodiment, gate contacts 182 a, 182 b are in contact with at least a portion of gate conductor 116 a, 116 b of gate structures 110 a, 110 b. Gate contacts 182 a, 182 b may include portions of liner layer 148 and portions of metal 178. Liner layer 148 of gate contacts 182 a, 182 b may directly contact gate conductor 116 a, 116 b. Liner layer 148 and metal 178 of gate contacts 182 a, 182 b may be continuous with, and formed at the same time as, liner layer 148 and metal 178 of source/drain contacts 180 a, 180 b, 180 c as described according to methods according embodiments of the disclosure.

FIG. 17 shows a cross-sectional view of IC structure 190 taken along line B-B through source/drain contact line 180 b. As shown in FIG. 17, source/drain contact line 180 b includes contact line spacer 174 b comprising dielectric film 172 over source/drain epitaxial region 124 substantially surrounding fin 104. Spacer 174 b substantially isolates a first portion 184 a of source/drain contact line 180 b from a second portion 182 b of source/drain contact line 180 b. Each portion 184 a, 184 b may include portions of liner layer 148 and portions of metal 178. Portions 184 a, 184 b, may act as distinct contact lines. As shown, FIG. 18 shows a cross-sectional view of IC structure 190 taken along line C-C through source/drain contact line 180 c. As shown in FIG. 18, source/drain contact line 180 c includes source/drain contact line spacer 174 c comprising dielectric film 172 over STI region 138 substantially separating fin 104 from an adjacent fin. Spacer 174 c substantially isolates a first portion 186 a of source/drain contact line 180 c from a second portion 186 b of source drain contact line 180 c. Each portion 186 a, 186 b may include portions of liner layer 148 and portions of metal 178. Portions 186 a, 186 b, may act as distinct contact lines.

In conventional contact lines having contact lines spacers therein, the contact line spacers are substantially separated from the metal of the contact lines by the liner layer. That is, the liner layer of conventional contact lines also line the contact line spacers therein. As IC structures continue to scale down in size, the real estate on IC structures becomes more valuable. Thus, aspects of the present disclosure provide for the absence of such a liner layer immediately adjacent to the contact line spacer providing additional real estate to be used for the contact line metal. As such, the contact line spacers described herein are in direct contact with the contact line metal resulting in improved resistance as compared to conventional IC structures having contact line spacers.

It is to be understood that source/drain contact lines 180 a, 180 b, 180 c, and contact line spacers 174 a, 174 b, 174 c therein, are not limited to the orientations shown or described herein. Rather, as previously discussed, the design of IC structure 190 may be customized based on the desired application of IC structure 190 by altering the patterning and etching of mask 164 (FIGS. 10A-11B) and/or mask 140 (FIGS. 5A-6B). However, in any instance, contact line spacers fabricated according to embodiments of the disclosure as described with respect to FIGS. 1A-18, will not include a liner layer substantially separated the contact line metal from the contact line spacer. Further, any number of contact lines, contact line spacers, and gate contacts may be formed without departing from embodiments of the disclosure.

FIGS. 19A-23 show an IC structure according to another embodiment of the disclosure. In this embodiment, after contact line spacers 174 a, 174 b, 174 c (FIG. 13A) are formed and sacrificial material 152 (FIGS. 13A-13B) is removed as discussed relative to FIGS. 14A-14B, another liner layer 210 may be formed over IC structure 100 as shown in FIGS. 19A-19B. In such an embodiment, liner layer 210 may be formed over exposed portions of liner layer 148 and contact line spacers 174 a, 174 b, 174 c. Liner layer 210 may include any of the materials discussed relative to liner layer 148. However, liner layer 210 may be formed to have a thickness of approximately 0.5 nm to approximately 5 nm. As discussed herein, liner layer 148 may have a thickness of approximately 1 nm to approximately 10 nm. As such, liner layer 210 may be thinner than liner layer 148. As shown, liner layer 210 may be formed to substantially coat exposed liner layer 148 within trenches 139 a, 139 b, 139 c (FIG. 19B). Liner layer 210 may also be formed over contact liner spacers 174 a, 174 b, 174 c outside of trenches 139 a, 139 b, 139 c.

As shown in FIGS. 20A-20B, metal 178 may be formed as described with respect to FIGS. 15A-15B. Subsequently, IC structure 100 may undergo a planarization process such that material outside of trench openings 139 a, 139 b, 139 c are removed and become planar with ILD layer 132 to create a resulting IC structure 290 having source/drain contact lines 220 a, 220 b, 220 c as shown in FIGS. 21A-21B.

IC structure 290 may include ILD layer 132 over a set of fins, e.g., including fin 104 (FIG. 16B). Within ILD layer 132, one or more gate structures 110 a, 110 b may be disposed perpendicular to fins, e.g., fin 104, such that gate structure 110 a, 110 b substantially surround fins, e.g., fin 104. Further, source/drain epitaxial regions 124 may be disposed such that source/drain epitaxial regions 124 (FIG. 16B) are over and substantially surround the fins, e.g., fin 104. Source/drain epitaxial regions 124 may be disposed on opposing sides of gate structures 110 a, 110 b. Source/drain contact lines 220 a, 220 b, 220 c may be disposed over source/drain epitaxial regions 124 (and/or in some cases, over STI region 138 (FIGS. 12A)) within ILD layer 132. Source/drain contact lines 220 a, 220 b, 220 c may include portions of liner layer 148 over source/drain epitaxial regions 124 (and/or in some cases, over STI region 138) within ILD layer 132. Source/drain contact lines 220 a, 220 b, 220 c may also include portions of liner layer 210 within liner layer 148. Additionally, source/drain contact lines 220 a, 220 b, 220 c may include metal 178 within liner layer 210. As known in the art, source/drain contact lines 220 a, 220 b, 220 c provide electrical connection between source/drain epitaxial regions 124 and structures which are to be fabricated in metal levels over ILD layer 132.

Source/drain contact lines 220 a, 220 b, 220 c may include contact line spacers 174 a, 174 b, 174 c therein. Contact line spacers 174 a, 174 b, 174 c may be composed of dielectric film 172 and provide electrical isolation between portions of source/drain contact lines 220 a, 220 b, 220 c such that the portions of source/drain contact lines 220 a, 220 b, 220 c separated by contact line spacers 174 a, 174 b, 174 c may be considered distinct source/drain contact lines.

In some embodiments, IC structure 290 may include gate contacts 222 a, 222 b which are in electrical connection with source/drain contact lines 220 a, 220 b, 220 c. In such an embodiment, gate contacts 222 a, 222 b are in contact with at least a portion of gate conductor 116 a, 116 b of gate structures 110 a, 110 b. Gate contacts 222 a, 222 b may include portions of liner layers 148, 210 and portions of metal 178. Liner layer 148 of gate contacts 222 a, 222 b may directly contact gate conductor 116 a, 116 b. Liner layers 148, 210 and metal 178 of gate contacts 222 a, 222 b may be continuous with, and formed at the same time as, liner layers 148, 210 and metal 178 of source/drain contacts 220 a, 220 b, 220 c as described according to methods according embodiments of the disclosure.

FIG. 22 shows a cross-sectional view of IC structure 290 taken along line B-B through source/drain contact line 220 b. As shown in FIG. 22, source/drain contact line 180 b includes contact line spacer 174 b comprising dielectric film 172 over source/drain epitaxial region 124 substantially surrounding fin 104. Spacer 174 b substantially isolates a first portion 224 a of source/drain contact line 220 b from a second portion 224 b of source/drain contact line 220 b. Each portion 224 a, 224 b may include portions of liner layers 148, 210 and portions of metal 178. As shown, FIG. 23 shows a cross-sectional view of IC structure 290 taken along line C-C through source/drain contact line 220 c. As shown in FIG. 18, source/drain contact line 220 c includes source/drain contact line spacer 174 c comprising dielectric film 172 over STI region 138 substantially separating fin 104 from an adjacent fin. Spacer 174 c substantially isolates a first portion 226 a of source/drain contact line 220 c from a second portion 226 b of source drain contact line 220 c. Each portion 226 a, 226 b may include portions of liner layers 148, 210 and portions of metal 178.

In conventional contact lines having contact line spacers therein, the contact line spacers are substantially separated from the metal of the contact lines by the liner layer. That is, the liner layer of conventional contact lines also line the contact line spacers therein. As IC structures continue to scale down in size, the real estate on IC structures becomes more valuable. Thus, aspects of the present disclosure according to this embodiment provide for a thinner liner layer immediately adjacent to the contact line spacer providing additional real estate to be used for the contact line metal. The thinner liner layer described herein is formed after the formation of the contact liner spacer and before the contact line metal. As such, the IC structures formed according to this embodiment result in improved resistance as compared to conventional IC structures having contact line spacers.

It is to be understood that source/drain contact lines 220 a, 220 b, 220 c, and contact line spacers 174 a, 174 b, 174 c therein, are not limited to the orientations shown or described herein. Rather, as previously discussed, the design of IC structure 290 may be customized based on the desired application of IC structure 290 by altering the patterning and etching of mask 164 (FIGS. 10A-11B) and/or mask 140 (FIGS. 5A-6B). However, in any instance, contact line spacers fabricated according to this embodiment of the disclosure as described with respect to FIGS. 19A-23, will include a thinner liner layer substantially separating the contact line metal from the contact line spacer. Further, any number of contact lines, contact line spacers, and gate contacts may be formed without departing from embodiments of the disclosure.

The methods as described above are used in the fabrication of integrated circuit chips. The resulting integrated circuit chips can be distributed by the fabricator in raw wafer form (that is, as a single wafer that has multiple unpackaged chips), as a bare die, or in a packaged form. In the latter case the chip is mounted in a single chip package (such as a plastic carrier, with leads that are affixed to a motherboard or other higher level carrier) or in a multichip package (such as a ceramic carrier that has either or both surface interconnections or buried interconnections). In any case the chip is then integrated with other chips, discrete circuit elements, and/or other signal processing devices as part of either (a) an intermediate product, such as a motherboard, or (b) an end product. The end product can be any product that includes integrated circuit chips, ranging from toys and other low-end applications to advanced computer products having a display, a keyboard or other input device, and a central processor.

The descriptions of the various embodiments of the present disclosure have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein. 

We claim:
 1. An integrated circuit structure comprising: a contact line being disposed within a dielectric layer and providing electrical connection to source/drain epitaxial regions surrounding a set of fins, the contact line including: a first portion of the contact line electrically isolated from a second portion of the contact line by a contact line spacer, wherein the first portion and the second portion each include a liner layer and a metal, the liner layer separating the metal from the dielectric layer and the source/drain epitaxial regions, and wherein the metal is directly in contact with the contact line spacer.
 2. The integrated circuit structure of claim 1, wherein the contact liner spacer includes a nitride or an oxide.
 3. The integrated circuit structure of claim 1, wherein the metal includes at least one of: tungsten, cobalt, or copper
 4. The integrated circuit structure of claim 1, wherein the liner layer includes at least one of: titanium, titanium nitride, tantalum, or tantalum nitride.
 5. The integrated circuit structure of claim 1, further comprising: a gate contact line providing electrical connection to a gate conductor of a gate structure and the contact line, the gate contact line including: a portion of the liner layer in direct contact with the gate conductor, and a portion of the metal over the liner layer that is in direct contact with the gate conductor. 